warning MITSUBISHI LANCER EVOLUTION VIII 2004 Workshop Manual

ENGINE (4G6) – GENERAL, BASE ENGINE (6 M/T)18
Control system (6M/T)
The following changes have been made, based on the control system in the 4G63DOHCT/C engine fitted in the current
Lancer Evolution VIII.
* Addition of wastegate solenoid valve (1 valve –> 2 valves)
System Block Diagram
Air flow sensor (AFS)
Air temperature sensor
Atmospheric pressure sensor
Water temperature sensor
Throttle position sensor (TPS)
A/C switch
A/C load signal
Cam position sensor
Crank angle sensor
Alternator FR terminal
Vehicle speed sensor
Power steering fluid pressure
switch
Knock sensor
Intercooler water spray (auto)
Intercooler water spray (manual)
O
2sensor
Ignition switch –IG
Ignition switch –STPower supplyEngine ECU
Fuel injection control
Idle speed control (ISC)
Ignition timing control
Engine control relay control
Fuel pump relay control
A/C relay control
Fan motor control (radiator)
Fan relay control (A/C
condenser)
Alternator control
Air flow sensor filter reset
control
Fuel pressure control
Supercharging pressure
control
Secondary air controlIntercooler water spay control
Engine warning light control
O
2sensor heater control
Purge control
Diagnosis output
RAM data transmissionNo. 1 indicator
No. 2 indicator
No. 3 indicatorNo. 4 indicator
ISC servo (stepper motor)
Ignition coil A (No.1 – No.4)
Ignition coil B (No.2 – No.3)
Engine control relay
Fuel pump relay 2
Fuel pump relay 3
A/C relay
Fan controller (radiator fan)
Fan motor relay (HI, LOW)
(A/C condenser)
Alternator G terminal
Air flow sensor
Fuel pressure control valve
No. 1 wastegate solenoid valve
No. 2 wastegate solenoid valve
Secondary air control solenoid
valve
Intercooler water spray relay
Intercooler water spray lamp
Tachometer
Engine warning lights O
2sensor heater
Purge control solenoid valve
Diagnosis output terminal
Diagnosis output terminal (for
MUTII)

REFERENCE MA
TERIAL – MAIN EQUIPMENT, COLD CLIMATE SPECIFICATIONS88
4WD
RSGSR
Equipment
5/MT6/MT
ABSrll
SRS airbags
Fuel level
Parking brake
Charge
Brake fluid
Engine check
Warning
lights
Door not properly closed
Lighting monitor warningBuzzer
Ignition key reminder warning
lll
Fixed time
intermittentll
Variable
intermittent(speed
sensitive)l
Windscre
en wipers2 speed
Mist spray
Equip
ment
Windscreen washer (synchronized with
wiper, 4jet)
lll
4WD
RSGSR
Equipment
5/MT6/MT
Rear
windowwiper /
washerFixed time intermittent,
synchronized with (R) gearpositionl
AM/FM tuner radio + MD player
+ DVDMMCS (DVD navigation
Mitsubishi MultiCommunication
System)r
Roof aeriallll
Roof and window aerial (diversity
aerial)r
W/out audiolll
Audio
parts
6 speakers (2 DIN compatible)r*3
Digital clock
Immobiliser system
lll
Manual heater
Air conditioning kit
ll
Equip
ment
Air
conditioning
Fully automatic air
conditioningl
Notes:
*3: Brackets for an aerial and radio are installed as standard.
Cold Climate Specifications
4WD
RSGSR
Equipment
5M/T6M/T
Battery
Weather strip silicon coating
Rear seat heater duct
Cold Climate Specification label
rrr
Door mirrors with heating elementsr

MPI General13A2
General
Service information issued contains the changes noted below. Other service details remain unchanged.
• Change from one to two wastegate solenoid valves. However, the No.2 wastegate solenoid valve on the 5 M/T is not
functional.
• Diagnosis code No. P1500 changed to P0622. <6M/T>
MPI system diagram
1.O2 sensor2. Air flow sensor3. Air intake sensor4. Throttle position
sensor
5. Cam position sensor6. Crack angle sensor7.Barometric pressure
sensor
8. Water temperature
sensor
9. Knock sensor•Power supply
• Ignition switch IG
• Ignition switch ST
•Vehicle speed sensor
• A/C switch
• A/C load signal
•Power steering fluid
pressure switch
•Alternator FR signal
•Intercooler water spray
switch (auto)
•Intercooler water spray
switch (manual)
1.Injector2. ISC servo (stepper
motor)
3.Fuel pressure control
solenoid valve
4.No.1 wastegate solenoid
valve
5. No.2 wastegate solenoid
valve
6. Purge control solenoid
valve
7. Secondary air control
solenoid valve•Engine control relay
•Fuel pump relay 2, 3
• A/C relay
•Ignition coil
• Fan controller
• Condenser fan relay (HI)
•Condenser fan relay
(LOW)
•Engine warning lamp
•Diagnosis output
• Alternator G terminal
•Intercooler water spray
relay
•Intercooler water spray
lamp
Engine ECU
6.Purge control
solenoid valveCanister
7.Secondary air
control solenoid valveFrom fuel tank
Secondary
air valveBypass
valve
1. O2sensor
3.Fuel pressure
control solenoid valve
4.Throttle
position
sensor
7. Barometric pressure
sensor
3. Air intake
sensor2. Air flow sensor
4. No.1
wastegate
solenoid valve
5.No.2 wastegate
solenoid valve
Only operates on 6M/TWastegate actuatorFuel pressure
regulator
1. Injector5.Cam position sensor8.Water temperature sensor
9.Knock sensor
Crack angle sensor
Catalytic converter Air
intakeCheck
valve
2.ISC servo
Vacuum
tank
From fuel
pump To fuel
tank

Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor <FR>
• No.02 Vehicle speed sensor <FL>
• No.03 Vehicle speed sensor <RR>
• No.04 Vehicle speed sensor <RL>
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
•Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor
<FR>)
(2) Resistance between 6 19 (vehicle speed sensor
<FL>)
(3) Resistance between 7 20 (vehicle speed sensor
<RR>)
(4) Resistance between 8 – 21 (vehicle speed sensor
<RL>)
OK:1.2 – 1.6kΩ
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector:C38
NG > repair
MUTII/III Service data
• No.1 Vehicle speed sensor <FR>
• No.2 Vehicle speed sensor <FL>
• No.3 Vehicle speed sensor <RR>
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle wheel speed sensor
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG: Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
• Check output wire for broken wire, earthing, short
• Check earth wire to see if broken or damaged
NG:repair
MUTII/III Service data
•No.1 Vehicle speed sensor <FR>
•No.2 Vehicle speed sensor <FL>
• No.3 Vehicle speed sensor <RR>
• No.4 Vehicle speed sensor <RL>
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunction
Vehicle wheel speed sensor and rotor check
(Refer to Group 35B – Vehicle Wheel Speed Sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
MANUAL TRANSMISSION TROUBLESHOOTING225
Code No.25 Abnormal tyre diameterAssumed cause of concern
Abnormal tyre Code No. 25 is output in cases where, when
the steering wheel is in a central position, and vehicle speed
is 20kph or more, there is a discrepancy between one of the
vehicle wheel speed sensors and the average of the 4 wheel
speed sensors, in that it is outside the specified range.However, the warning lamp does not come on.• Tyre malfunction
•Vehicle speed sensor malfunction
• Rotor malfunction
• Wheel bearing malfunction
• Harness, connector malfunction
<ACD fitted vehicles>
Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK NG
NG
OK
NG
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING226
Vehicle speed sensor fitting check
NG > repair
MUTII/III Service Data
• No.01 Vehicle speed sensor <FR>
• No.02 Vehicle speed sensor <FL>
•No.03 Vehicle speed sensor <RR>
•No.04 Vehicle speed sensor <RL>
OK:Speed shown on speedometer and MUTII/III agree
OK > Intermittent malfunction
Measurement at C38 4WDECU connector
• Undo connector and take measurement on harness
side
(1) Resistance between 9 – 22 (vehicle speed sensor
<FR>)
(2) Resistance between 6 19 (vehicle speed sensor
<FL>)
(3) Resistance between 7 20 (vehicle speed sensor
<RR>)
(4) Resistance between 8 – 21 (vehicle speed sensor
<RL>)
OK:1.2 – 1.6kΩ
Check vehicle wheel speed sensor output voltage (ref.
p.2241)
*2
Check connector:C38
NG > repair
MUTII/III Service data
• No.1 Vehicle speed sensor <FR>
• No.2 Vehicle speed sensor <FL>
• No.3 Vehicle speed sensor <RR>
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunctionVehicle wheel speed sensor
(Refer to Group 35B – Vehicle wheel speed sensor)
*1
NG > Repair
Connector checks:C38, A05, A31, D11, D05,
D12, C131, C20, C115, C34
NG > Repair
Harness check between 4WDECU – each vehicle
wheel speed sensor
• Check output wire for broken wire, earthing, short
• Check earth wire to see if broken or damaged
NG > repair
MUTII/III Service data
•No.1 Vehicle speed sensor <FR>
• No.2 Vehicle speed sensor <FL>
• No.3 Vehicle speed sensor <RR>
• No.4 Vehicle speed sensor <RL>
OK:Speed shown on speedometer and MUTII/III
agree
NG > Replace 4WDECU
OK > Intermittent malfunction
Vehicle wheel speed sensor and rotor check
(Refer to Group 35B – Vehicle Wheel Speed Sensor)
*1
NG > Repair
Wheel bearing check (Refer to Group 26 – Vehicle
Servicing, Group 27B – Rear Hub Assembly)
*2
NG > Repair
Code No.26 Vehicle wheel speed sensor system (output
signal abnormal)Assumed cause of concern
Abnormal vehicle wheel speed sensor Code No. 26 is output
in cases where, when the vehicle speed is 20kph or more,
one of the vehicle wheel speed sensors is outside the
specified range. However, the warning lamp does come on.•Tyre malfunction
• Vehicle speed sensor malfunction
•Rotor malfunction
• Wheel bearing malfunction
•Harness, connector malfunction
• 4WDECU malfunction
<ACD fitted vehicles>
Remarks*1: refer to ’005 Lancer Sedia Service Manual (No.1036K00)*2: refer to ’011 Lancer Evolution VII Service Manual (No.1036K02)
OK
OK
OK
OK NG
NG
OK
NG
OK
OK
OK

MANUAL TRANSMISSION TROUBLESHOOTING2216
Code No.63 Parking brake switchAssumed cause of concern
In cases where, at 15kph or over, the parking brake switch
remains ON for 15 minutes or more, code No.63 is output.• Parking brake switch malfunction
•Harness, connector malfunction
• ABSECU malfunction, <ACD+AYC fitted vehicles>
•4WDECU malfunction
Remarks*1: Refer to ’005 Lancer Sedia Service Manual (No.1036K00)
MUTII/III Service data
• No.62 Parking brake switch
(1)Apply parking brake lever
OK:ON
(2)Release parking brake lever
OK:OFF
OK > intermittent malfunction
When parking brake lever is
released, does the brake
warning lamp go off?
Measurement at D25, parking
brake switch connector
•Undo connector, take
measurement on harness side
•Ignition switch: ON
• Voltage between 1 – earth
OK:battery voltage
Connector check:D25
NG > repair
Check, and if necessary adjust,
the play in the parking brake
lever
(refer to Group 36 – Vehicle
Servicing)
*1
NG > Adjust
Check parking brake switch
(refer to Group 36 – Vehicle
Servicing)
*1
NG > adjust
Connector check:C37, D25,
C20NG > repair
Connector check:D25, C37,
C20, B109 <ACD + AYC fitted
vehicles>
D25, C20, C37 <ACD fitted
vehicles>
NG > repair
(1)Check harness between
parking brake switch – 4WD
ECU
• Check output wire for
earth, damage
(2)Check harness between
parking brake switch –
combi.meter
• Check power supply wire
for earth, damage
(3) Check harness between
parking brake switch – ABS
ECU.
<ACDAYC fitted vehicles>
• Check output wire forearth, damage
NG > repair
Replace hydraulic unit, ABS
ECUCheck harness between
parking break switch – 4WD
ECU
• Check output wire to see if
broken or damaged
NG > repair
MUTII/III Service data
• No.62 Parking brake switch
(1)Apply parking brake lever
OK:ON
(2)Release parking brake lever
OK:OFF
NG > replace 4WDECU
OK > intermittent malfunction
Check brake warning lamp bulb
NG > replace
Replace combi. meter
YESOK
(1) OK
(2) OK
NG
NG
NO
OK
OK
OK
(3) OK
OK
OK
OK

Related documentation
Cautionary Note regarding servicing of vehicles fitted with SRS airbags and/or seatbelts with
pre-tensioner systems.
Warnings:
1. Incorrect inspection or servicing of a component part of the SRS airbag system or seatbelt pre-tensioner system, or
a part relating to these systems, may cause accidental operation (deployment) of the SRS airbag or seatbelt pre-
tensioners, or may cause these systems to be disabled, leading in either case the risk of serious injury.
2. If parts may be affected by heat during painting operations, then those parts must be removed in advance. This
applies to the SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front impact
sensors, side impact sensors, and pre-tensioner seatbelts.
• 93ºC or above : SRS-ECU, airbag modules (driver’s sear and front passenger’s seat), clock springs, front impact
sensors, side impact sensors
• 90ºC or above : Pre-tensioner seatbelts
3. The component parts of the SRS airbag system or seatbelt pre-tensioner system, and parts relating to these
systems, must always be inspected and serviced by a Mitsubishi dealer.
4. Service personnel must read the relevant service manuals (particularly, Section 52B – SRS Airbags) carefully and
thoroughly, before inspecting or servicing the component parts of the SRS airbag system or seatbelt pre-tensioner
system, and parts relating to these systems.
Title of Document No. Date of
IssueTitle of Document No. Date of
Issue
Body Manuals (Service Manual)
• Mirage, Lancer (supplement)
• Lancer Cedia
• Lancer Cedia (supplement)
• Lancer Evolution VII
(supplement)
• Lancer Cedia (supplement)
• Lancer (supplement)
• Lancer Evolution VIII MR
(supplement)1036F52
1036K50
1036K51
1036K52
1036K53
1036K54
1036K55Aug 1996
May 2000
July 2000
May 2001
Oct 2001
Feb 2003
Feb 2004
Electrical Wiring Diagrams
Service Manual
• Lancer Evolution VIII 1036K77 Jan 2003
New Vehicle Manuals
• Mirage, Lancer
• Mirage, Lancer
• Mirage, Lancer
• Mirage, Lancer
• Mirage
• Mirage, Lancer
• Lancer
• Lancer
• Lancer Cedia
• Lancer Cedia
• Lancer Evolution VII
• Lancer Cedia
• Lancer Cedia
• Lancer Evolution VII
• Lancer Cedia
• Lancer Evolution VIII
• Lancer
• Lancer
• Lancer Evolution VIII MR1036F30
1036F31
1036F32
1036F33
1036F34
1036F35
1036F36
1036F37
1036K30
1036K31
1036K32
1036K33
1036K34
1036K35
1036K36
1036K37
1036K38
1036K39
1036K40Oct 1995
Jan 1996
Aug 1996
Jul 1997
Jan 1998
Oct 1998
Jan 1999
Dec 1999
May 2000
July 2000
Jan 2001
May 2001
Oct 2001
Jan 2002
May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004Engine Service Manual
• 4G6 Engine
• 4G6 Engine (supplement)1039G46
1039G63Jan 2001
Jan 2003
Service Manuals
• Lancer Cedia
• Lancer Cedia (supplement)
• Lancer Evolution VII
(supplement)
• Lancer Cedia (supplement)
• Lancer Cedia (supplement)
• Lancer Evolution VII
(supplement)
• Lancer Cedia (supplement)
• Lancer Evolution VIII
(supplement)
• Lancer (supplement)
• Lancer (supplement)
• Lancer Evolution VIII MR
(supplement)1036K00
1036K01
1036K02
1036K03
1036K04
1036K05
1036K06
1036K07
1036K08
1036K09
1036K10May 2000
July 2000
Jan 2001
May 2001
Oct 2001
Jan 2002
May 2002
Jan 2003
Feb 2003
Dec 2003
Feb 2004Transmission Service Manual
• W5M51 Manual Transmission
• W5M51 Manual Transmission
(supplement)
• W6MAA Manual Transmission1039M17
1039M22
1039M23Jan 2001
Jan 2003
Jan 2003

GENERAL INFORMATION - DETAILS OF CHANGES0-3
Main circuit Name of circuit Page Details of change
J/C - p.3-2• Partial changes to circuit and
destination system names in J/C(1) —
(6)
-• With the introduction of manual air
conditioning, the circuit used by the
fusible link No.2 has been changed.
• Wastegate solenoid valve 2 added to
load of special fuse No.3.
• Rating of special fuse No.10 changed
from 15A to 20A.
Power supply - p.3-10• Partial changes to destination system
names.
• Earth No.13 added.
• Rating of special fuse No.10 changed
from 15A to 20A.
• Partial changes to circuit details, due
to removal of sunroof.
Engine control - p.3-16• Rating of special fuse No.10 changed
from 15A to 20A.
• Earth No.13 added.
• Some changes to circuit, due to
addition of wastegate solenoid valve
2 (B-32).
• Partial changes, due to removal of
DVD-MMCS
Lighting Interior lights, boot interior
light, ignition key cylinder
illumination light, door not
closed indicator light-• Change to terminal number in J/C(2)
(C-119) on line linking ETACS and
diagnosis connector. (No.1 " No.5)
Reversing lights -• Change to terminal number in J/C(2)
(C-119) on line linking reversing light
and rear combination light (LH).
(No.18 " No.19)Signal
Stop lights p.3-24• Spare connector (F-28) added, and
circuit partially changed.
Meters / Gauges -Meters
Remaining fuel warning
light, oil pressure warning
light, brake warning light,
seatbelt warning light-• Change to terminal number in J/C(1)
(C-07) on line inking J/B (general fuse
No.18) and combination meter. (No.4
" No.8)
• Change to terminal number in J/C(4)
(C-110) on line linking combination
meter and fuel gauge unit (sub).
(No.20 " No.21)
Door opening
controlElectric windows -• Change to terminal number in J/C(2)
(C-119) on line linking power window
main switch and diagnosis connector.
(No.12 " No.14)
Fully automatic air
conditioning-• Change to terminal number in J/C(1)
(C-07) on line linking J/B (general
fuse No. 18) and A/C-ECU. (No.6 "
No.4)
• Change to terminal number in J/C(5)
(C-06) on line linking A/C-ECU and
diagnosis connector. (No.8 " No.9)Air
conditioning
Manual air conditioning p.3-26• With the adoption of manual air
conditioning, a new circuit has been
installed.
Windscreen wipers and
washers-Safety and
visibility
Electric retractable remote
control door mirrors-• Change to terminal number in J/C(2)
(C-119) on line linking ETACS and
diagnosis connector. (No.1 " No.5)
Circuit diagrams
M3000004500157

GENERAL INFORMATION - LIST OF CIRCUIT DIAGRAMS0-5
Main circuit Name of Circuit Circuit Diagram
J/B -!
J/C -#
Central junction -#
Power supply -#
Start up -!
Ignition -!
Charging -!
Engine control -#
Coolant -!
Headlights (excluding discharge type)!
Headlight (discharge type)!
Tail lights, side lights, licence plate lights, lighting monitor
warning buzzer!
Cabin lights, boot interior light, ignition key cylinder
illumination light, door not closed indicator light *2!
Fog lights!
Lighting
Headlight levelling system
!
Indicator lights, hazard warning lights!
Reversing lights *2!
Stop lights#
Signalling
Horn
!
Meters / Gauges *2!Meters
Remaining fuel warning light, oil pressure warning light,
brake warning light, seatbelt warning light *2
!
Electric windows *2!
Central door locking (vehicle not fitted with keyless entry)!
Door opening control
Central door locking (vehicle fitted with keyless entry)
!
Heater!
Fully automatic air conditioning!
Air conditioning
Manual air conditioning
#
List of Circuit Diagrams
M3000006000169
Notes:
1. This list of circuit diagrams indicates whether each circuit has been modified or added.
2. The “●” symbol indicates a circuit that has been modified or added. Diagrams for these circuits are included in
this supplement.
3. The “


” symbol indicates a circuit that is unchanged. Details of these circuits can be found in the existing
Electrical Wiring Diagram manual (’03-1 No.1036K77).
4. The “X” symbol indicates a circuit that is unrelated to the vehicle referred to in this manual.
5. The “*1” symbol marks circuits whose names have been changed the previous names.
6. The “*2” symbol marks circuits whose J/C terminal numbers have changed. For more information, please refer
to the “Details of Changes” table above.

COMPONENT INSTALLATION POSITIONS - J/C3-2
J/C
Note :
In an actual vehicle, any of the terminals connected in the J/C
may be used. Therefore, the terminal numbers given in the
circuit diagrams may not coincide with the terminal arrangement
in the actual vehicle.
• Windscreen wiper
& washer
• Indicator lights,
hazard warning
lights
• Tail lights, side
lights, licence
plate lights,
lightning monitor
warning buzzer• Fog lights
• Headlights
• Headlight levelling
system
• Rear wiper /
washer
Full auto
A/C
General
spare
connector
Clock
Spare audio
connector
• Warning
lights
• Meter
gauge
• ACD
• Engine
control
J/B
General fuse
()18
General
spare
connector
Fog light
Spare audio
connector
• Demister (Vehicle
w/out full auto A/C)
• Demister, door
mirror heating
element (vehicle
with full auto A/C)
• Heater
• Full auto A/C
• Manual A/C
Cigar lighter
Ashtray
illumination
light
Clock
ACD
Headlight
levelling
system
Indicator light
Hazard
warning lights
Intercooler
water spray
General fuse15
• Meter gauge
• Tail lights, side
lights, licence
plate lights,
lighting monitor
warning buzzer